US4671470A - Method for fastening aircraft frame elements to sandwich skin panels covering same using woven fiber connectors - Google Patents

Method for fastening aircraft frame elements to sandwich skin panels covering same using woven fiber connectors Download PDF

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Publication number
US4671470A
US4671470A US06/754,951 US75495185A US4671470A US 4671470 A US4671470 A US 4671470A US 75495185 A US75495185 A US 75495185A US 4671470 A US4671470 A US 4671470A
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United States
Prior art keywords
groove
strands
fill
facesheet
yarn
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US06/754,951
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English (en)
Inventor
Paul J. Jonas
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Beechcraft Corp
Original Assignee
Beech Aircraft Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=25037085&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=US4671470(A) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Assigned to BEECH ARCRAFT CORPORATION, A CORP. OF DE. reassignment BEECH ARCRAFT CORPORATION, A CORP. OF DE. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: JONAS, PAUL J.
Priority to US06/754,951 priority Critical patent/US4671470A/en
Application filed by Beech Aircraft Corp filed Critical Beech Aircraft Corp
Priority to GB8620005A priority patent/GB2193698B/en
Priority to EP86306356A priority patent/EP0257148B1/en
Priority to DE8686306356T priority patent/DE3685586T2/de
Priority to AU61763/86A priority patent/AU585055B2/en
Priority to FR8612141A priority patent/FR2603249B1/fr
Priority to DE8623542U priority patent/DE8623542U1/de
Publication of US4671470A publication Critical patent/US4671470A/en
Application granted granted Critical
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D25/00—Woven fabrics not otherwise provided for
    • D03D25/005—Three-dimensional woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like
    • B29C65/5028—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being textile in woven or non-woven form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5064—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped
    • B29C65/5071—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped and being composed by one single element
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5064—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped
    • B29C65/5085—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped and comprising grooves, e.g. being E-shaped, H-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/112—Single lapped joints
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    • B29C66/114—Single butt joints
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
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    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1244—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
    • B29C66/12443—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue having the tongue substantially in the middle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4326—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms for making hollow articles or hollow-preforms, e.g. half-shells
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4344—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces
    • B29C66/43441—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces with two right angles, e.g. for making T-shaped pieces, H-shaped pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4346—Joining substantially flat articles for forming cross connections, e.g. for making X-shaped pieces
    • B29C66/43461—Joining substantially flat articles for forming cross connections, e.g. for making X-shaped pieces with four right angles, e.g. for making +-shaped pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
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    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/222—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being shaped to form a three dimensional configuration
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
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    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D24/00—Producing articles with hollow walls
    • B29D24/002—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled
    • B29D24/004—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled the structure having vertical or oblique ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0003—Producing profiled members, e.g. beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C1/06—Frames; Stringers; Longerons ; Fuselage sections
    • B64C1/12—Construction or attachment of skin panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
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    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like

Definitions

  • these sheet materials can be fabricated out of so-called “endless” filaments which are bundled together and twisted to form strands of yarn that are then woven, laminated together and otherwise manipulated and adhesively-bonded into sheets that comprise the "skin" of the panel.
  • the resulting “sandwich” becomes, therefore, the basic covering material.
  • Straps or bands woven out of the endless yarn strands are not only two dimensional but, in addition, can be woven into a fabric which is comprised of even more complex shapes that are three dimensional in that one or more integrally-formed substructures in the form of webs intersect the plane of the two dimensional sheet.
  • the method soon to be described which forms the subject matter herein disclosed and claimed uses such a three dimensional woven multifilament yarn product in the form of an elongate strap or band.
  • Sandwich constructions of the type just described exhibit the properties of a beam with the core corresponding to the web while the facesheets function in the manner of the flanges. These facesheets carry the axial, tensile and compressive loads, whereas, the core sustains the shear and compressive stresses normal to the skin and thus prevents wrinkling or buckling under axial compressive loads.
  • the second method was similar to the first in many respects except that a span-wise strip of resin having a higher density than the rest of the core was integrated into the skin panel underlying both the spar and the outstretched legs of the L-shaped connectors adhesively attached to the inner facesheet.
  • This method was somewhat simpler in that it did not require cutting a channel through the core and then filling it up again with a higher density core.
  • the continuity of the core across the joint remained along with its ability to transfer shear. Probably the only real shortcomings of this last method was its inherent increase in weight and the fact that it became much more labor-intensive.
  • Fabric straps or bands folded lengthwise into an L-shape and bonded or otherwise adhered to adjoining surfaces of the spars or other frame elements and skin panels where they meet to define a sharply-angled corner offers a solution to the skin penetration problem and such joints are widely used although they have somewhat more of a tendency to pull away from the corner if overstressed than a joint where the web of the fabric does not have to be folded into an inside corner.
  • crossbar portion of the H-shaped strap or band projects laterally on both sides beyond its transversely-spaced intersecting webs of the woven connector that define what will be referred to here as the "upright portions” of the "H".
  • the aforementioned crossbar portion forms the means for bridging the gap which is produced in the inner facesheet of the skin panel that has been cut apart when the groove is routed therein adjacent which the spar or other analogous frame element will be fastened.
  • the "fill" strands of this crossbar portion when adhesively-bonded to the inner facesheet adjacent the groove edges, re-establish its continuity across the joint.
  • Both upright portions of the strap do likewise by establishing an adhesively-bonded woven fabric bridge interconnecting the edges of the core exposed at the sides of the groove in the skin panel and the more or less aligned faces of the spar positioned proximal thereto. Any chordwise bending load tending to widen the gap in the inner facesheet is resisted by these same fill filaments in the crossbar portion of the H-connector that bridge the latter and which are placed in tension or compression. In the same way, any load tending to pull the spar out of the channel formed by the medial section of the crossbar portion and the limbs of the upright portions bonded to its sides is resisted by the entire upright portions of the H-connector as their corresponding "fill" filaments are placed in tension.
  • the tensioned fill filaments bridging the gap or those extending vertically alongside the latter must give way by breaking, stretching or fracturing the adhesive shear bond since no filament in the connector goes around this corner, just straight through the intersection.
  • the filling of the channel or void between the legs of the tape connector that will eventually be seated in the groove and adhesively attached to the edges of the core exposed within the latter has, as its principal function, that of backing up these connector legs thus insuring that they make broad area contact with the adjacent core surfaces resulting in a secure bond between them. Bridging the gap left by the groove in the core material with the rigid foam insert between the aforementioned legs of the connector does, of course, restore its continuity and, at least to some extent, its ability to transfer the shear load across the gap.
  • the warp strands of the connector are interwoven among the fillstrands at right angles thereto in the manner of the more common woven fabric structures; however, the fill strands of the crossbar portion which for purposes of the present description will be said to extend horizontally are spread apart at spaced intervals to produce the gaps through which the vertically-extending fill strands of the upright portions of the H-connector pass, and vice versa.
  • the warp strands are not without function in the woven connector used in accordance with the teaching of the instant invention since they resist the compression loads experienced primarily by the inner facesheets of the skin sandwiches and the tension and compression loads applied to the outer facesheets as the wing is bent about chordwise axes.
  • the principal object of the present invention to provide a novel and improved method for fastening aircraft wing spars and analogous frame elements to fiber-reinforced composite structures using a generally H-shaped woven strap connector.
  • a second object of the invention is the provision of a method of the type aforementioned that uses a woven H-shaped connector as the means for effecting an adhesively-bonded shear load tie between both the inner and outer facesheets of a sandwich construction skin panel and a sandwich web panel.
  • Another object of the invention herein disclosed and claimed is to restore the continuity of the inner facesheet in a grooved sandwich type composite skin panel by bridging the gap therein caused by the groove using equivalent strength fibers woven into the crossbar portion of an H-shaped woven connector adhesively-bonded thereto.
  • Still another objective of the invention is the provision of a method for fastening sandwich construction skin panels to sandwich web frame members which utilizes a woven H-connector that includes intersecting webs, the fill filament bundles of which are not bent around corners but instead remain essentially straight and thus fully capable of resisting tension loads applied to their ends.
  • An additional objective is the provision of a "slip-joint" attainable through the use of one pair of spaced parallel limbs in the upright portions of the H-connector which allows for considerable assembly tolerance when the spar or other frame element is connected to the skin panel.
  • FIG. 1 is a fragmentary view, partly in section, showing in perspective a portion of an aircraft wing which includes the spanwise spars and the skin panels, all of which have been illustrated as being of sandwich construction and joined together by an H-shaped woven connector to define a box beam;
  • FIG. 2 is a fragmentary perspective view, partly in section and much like FIG. 1 but to a greatly enlarged scale, showing the elements of the joint assembly preparatory to being moved into final position and bonded together;.
  • FIG. 3 is a fragmentary perspective view like FIG. 2 and to the same scale showing the completed joint;
  • FIG. 4 is a fragmentary perspective view like the preceding figures and to approximately the same scale as FIGS. 2 and 3 showing the woven fiber H-shaped connector used to join the spars to the skin panels before it is laid up in the forming tool and treated to rigidify same;
  • FIG. 5 is a still further enlarged fragmentary perspective view showing a portion of the woven connector with particular emphasis upon the weave of the yarn strands, both fill and warp, that make it up;
  • FIG. 6 is a fragmentary plan view to a much smaller scale than FIG. 5 revealing the weave pattern in which the fill strands are interwoven among the warp strands;
  • FIG. 7 is a diagram showing the manner in which the woven multifilament strap connector is impregnated with resin before being rolled and dried;
  • FIG. 8 is a diagram similar to FIG. 7 showing how the connector thus impregnated is laid up in a segmented forming tool which holds it in the desired shape while it is being autoclaved or otherwise treated to cure and harden same;
  • FIG. 9 is a fragmentary perspective view much like FIG. 4 but to a slightly larger scale showing the cured and rigidified connector with the foam insert in place therein;
  • FIG. 10 is a diagram illustrating the manner in which a section of an aircraft wing responds to bending loads.
  • FIG. 11 is a fragmentary perspective view very much like FIG. 3 except that it shows some of the major forces acting on the joint and the inner and outer facesheets of the lower sandwich skin panel it attaches to the spar web.
  • FIG. 1 shows a section of an aircraft wing in the form, of a box beam indicated in a general way by reference numeral 10 which is made up of fore and aft spars or frame elements given numerals 12 and 14, respectively; a center spar or frame element 16; upper and lower skin panels 18 and 20, respectively; one type of joint indicated broadly by reference numeral 22 shown connecting the upper and lower edges of the fore and center spars to the upper and lower skin panels; and quite a different joint 24 connecting the aft spar 14 to the rear skin panel edges.
  • reference numeral 10 which is made up of fore and aft spars or frame elements given numerals 12 and 14, respectively; a center spar or frame element 16; upper and lower skin panels 18 and 20, respectively; one type of joint indicated broadly by reference numeral 22 shown connecting the upper and lower edges of the fore and center spars to the upper and lower skin panels; and quite a different joint 24 connecting the aft spar 14 to the rear skin panel edges.
  • both the spar and panel can be seen as sandwich structures wherein a pair of facesheets are adhesively-bonded to opposite faces of a rigid core material.
  • the fore and aft facesheets 26 and 28, respectively, together with the core 30 therebetween when bonded together produce the spar web which is a special type of frame element, the function of which is to transfer shear as well as to hold the skin panels above and below the latter in precise fixed spaced relation to one another while cooperating with the ribs (not shown) to produce an airfoil.
  • the inner and outer facesheets, 32 and 34, respectively, of the lower skin panel 20 are adhesively-bonded top and bottom to a suitable core 36.
  • the method of using the woven fabric H-connector that has been indicated broadly by reference letter H to effect a connection between the aforementioned frame elements and sandwich skin panels is the subject of the instant invention.
  • the connector is generally H-shaped in cross section having a crossbar portion 38 intersected intermediate its side margins by a pair of transversely-spaced substantially parallel upright portions 40 and 42.
  • the crossbar portion 38 has flanges 44F and 44R projecting fore and aft of the upright portions 40 and 42 as shown.
  • the crossbar portion includes a medial web-forming section 44C located between the upright portions that cooperates with two of their limbs 40L and 42L on the same side thereof to define a foam-receiving channel 46.
  • this same medial section 44C of the crossbar portion cooperates with the remaining two limbs 40U and 42U of the uprights to define a second web-receiving channel 48.
  • the connector H is fabricated from multifilament strands of yarn Y interwoven to produce the H-shaped cross section previously described.
  • Each strand of yarn is made up of a plurality of individual hair-like fibers which may be glass, graphite, a material sold under the trademark "Kevlar" or whatever other substance one wishes to use having the properties required in the finished joint.
  • the warp strands carry the designation W while those of the fill are identified with the letter F.
  • the white arrows trace the course of a single fill strand making up the crossbar portion 38 of the connector H and particularly the aft flange 44R of the latter.
  • each fore and aft run thereof does not go up or down but rather extends right through the intersection formed by the strands of the upright portions 40 and 42 indicated by the black arrows and which are pushed aside to create a gap most clearly seen at 50 accommodating same.
  • the adjacent fill strands 38 of the crossbar portion identified by the white arrows are parted to create a gap through which the strands of the aforementioned upright portion 40 and 42 identified by the black arrows pass.
  • the warp strands W on the other hand, weave over and under adjacent strands of the crossbar portion as well as in front of and behind the adjacent strands of the upright portions.
  • the adjacent runs or lays of the fill strands F in both the crossbar portion and the upright portions of the connector lie in side-by-side parallel essentially contacting relation except at the intersections where they must be parted to create the gaps necessary for intersecting fill strands to pass through, all of which can be most easily followed by tracing the paths of the black and white arrows.
  • all the fill strands are continuous in that they are laid back and forth reversing direction at each end to produce a finished edge identified by the numeral 52 where one of the crossbar strands is shown passing over the top of the outermost warp strand on the near edge before reversing direction and passing back underneath the latter.
  • the warp strands W are not continuous, but rather, terminate at the remote ends of the tape as can best be seen in FIG. 6. It is worthy of mention, however, that this continuous strand construction found in the fill strands, while most desirable and by far the most practical from a weaving standpoint, is not critical from the perspective of the joint to be formed since each lay or run of all the strands, both fill and warp, are ultimately bonded to a facesheet, a side of the spar or the skin panel core exposed at the sides of the groove 56 routed in the skin panels that is revealed most clearly in FIG. 2. When thus bonded to an appropriate support structure, the fact that the strands terminate or, alternatively, wrap around a warp strand really has little if any structural significance.
  • the woven fiber connector H Before the woven fiber connector H can be laid up in the wing, it is preferably first passed through a bath as indicated schematically in FIG. 7 where it is impregnated with a suitable heat-curable resin. With the tape connector thus impregnated it is held and formed into the shape it will occupy in the finished assembly by means of a multi-segment forming tool 58 that has been illustrated somewhat schematically in FIG. 8.
  • the tool itself is designed to both hold and press against the flanges 44F and 44R of the crossbar portion 38 both top and bottom as well as the limbs 40U and 42U of the upright portions both fore and aft so as to maintain the filaments thereof in compacted relation to one another while they are being cured.
  • the medial section 44C of the crossbar portion 38 is supported by the tool only from above.
  • the tool with the connector spread out and its flanges thus compacted is then placed in a heat-resistant bag or envelope 60 and autoclaved or otherwise treated to cure same.
  • the connector H will be cured and in the precise shape required for the final assembly into the wing or other component.
  • the connector H will be as shown in FIG. 9 and already contain the structural foam filler 54.
  • the lower skin panel 20 has been shown grooved and ready to receive the foam-filled channel 46 of the connector.
  • Groove 56 is routed spanwise of the wing, both top and bottom, to receive the aforementioned foam-filled portion of the rigidified connector located either above or below the crossbar portion 38.
  • the gap produced by the groove 54 is filled although the foam filler has little, if anything to do with restoring the facesheets lost resistance to bending, the latter having been provided to some extent at least by the connector itself.
  • This same groove has cut through the inner facesheet 32 and thus destroyed its continuity.
  • the H-connector provides a structural joint joining the spar to both the inner and outer facesheets of the sandwich skin panels, both upper and lower.
  • the skin panels are, for all practical purposes, left continuous and undisturbed.
  • the grooves in the skin panels are replaced with the portions of the H-shaped connector bonded to the exposed edges thereof along with the foam filling the space between the two, the latter functioning to restore the continuous shear joint while, at the same time, backing up these portions of the connector thus insuring that they make the broad area contact with the skin panel core required for a reliable adhesively-bonded connection.
  • the gaps left in the inner facesheets are bridged by the crossbar portion of the H-connector extending thereacross and bonded to the facesheet surfaces adjacent the groove.
  • the upright portions of the H-connector provide a continuous load path between the spar webs and both the inner and outer facesheets.
  • the facesheets of the skin panels carry the axial tensile and compressive stresses while the core sustains the shear and compressive stresses normal to the skin and thus prevent the skin from wrinkling or buckling under axially-directed compressive loads.
  • a wing constructed in accordance with the above-described method using a woven H-shaped connector results in an efficient connection because, among other features, it utilizes a redundant double shear bond joint with the spar web. Also, assembly is simple and fast because the spar web need only be slipped into the opposed channels of the H-connectors sitting atop the grooves. Moreover, since these web-receiving channels are quite deep, it is not necessary that the spar web seat all the way to the bottom and this, of course, provides ample assembly tolerances.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Standing Axle, Rod, Or Tube Structures Coupled By Welding, Adhesion, Or Deposition (AREA)
  • Woven Fabrics (AREA)
  • Connection Of Plates (AREA)
  • Moulding By Coating Moulds (AREA)
US06/754,951 1985-07-15 1985-07-15 Method for fastening aircraft frame elements to sandwich skin panels covering same using woven fiber connectors Expired - Lifetime US4671470A (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
US06/754,951 US4671470A (en) 1985-07-15 1985-07-15 Method for fastening aircraft frame elements to sandwich skin panels covering same using woven fiber connectors
GB8620005A GB2193698B (en) 1985-07-15 1986-08-16 Joining of aircraft skin panels of the sandwich type to frame elements.
EP86306356A EP0257148B1 (en) 1985-07-15 1986-08-18 Improvements relating to the joining of aircraft skin panels of the sandwich type to frame elements
DE8686306356T DE3685586T2 (de) 1985-07-15 1986-08-18 Verbindung von flugzeugbeplankungsblech des sandwich-typs mit spantsegmenten.
AU61763/86A AU585055B2 (en) 1985-07-15 1986-08-22 Improvements relating to the joining of aircraft skin panels of the sandwich type to frame elements
FR8612141A FR2603249B1 (fr) 1985-07-15 1986-08-27 Raccord de panneau de revetement d'aeronef sur un organe porteur et son procede de realisation
DE8623542U DE8623542U1 (zh) 1985-07-15 1986-09-02

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US06/754,951 US4671470A (en) 1985-07-15 1985-07-15 Method for fastening aircraft frame elements to sandwich skin panels covering same using woven fiber connectors

Publications (1)

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US4671470A true US4671470A (en) 1987-06-09

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US06/754,951 Expired - Lifetime US4671470A (en) 1985-07-15 1985-07-15 Method for fastening aircraft frame elements to sandwich skin panels covering same using woven fiber connectors

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US (1) US4671470A (zh)
EP (1) EP0257148B1 (zh)
AU (1) AU585055B2 (zh)
DE (2) DE3685586T2 (zh)
FR (1) FR2603249B1 (zh)
GB (1) GB2193698B (zh)

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DE3685586T2 (de) 1993-01-21
EP0257148A1 (en) 1988-03-02
EP0257148B1 (en) 1992-06-03
DE8623542U1 (zh) 1988-01-07
AU585055B2 (en) 1989-06-08
FR2603249A1 (fr) 1988-03-04
AU6176386A (en) 1988-02-25
GB2193698A (en) 1988-02-17
GB2193698B (en) 1990-09-26
FR2603249B1 (fr) 1988-12-09
GB8620005D0 (en) 1986-09-24
DE3685586D1 (de) 1992-07-09

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